SEW Eurodrive BST Brake module Operating Instructions

Drive Technology \ Drive Automation \ System Integration \ Services

Operating Instructions

Safety-Related BST Brake Module

for Control Cabinet Installation

Edition 10/2011 19357214 / EN

SEW-EURODRIVE—Driving the world

Contents

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Contents

1 General Information............................................................................................ 5

1.1 How to use this documentation................................................................... 5

1.2 Structure of the safety notes ....................................................................... 5

1.2.1 Meaning of the signal words........................................................ 5

1.2.2 Structure of the section-related safety notes ............................... 5

1.2.3 Structure of the embedded safety notes...................................... 5

1.3 Right to claim under warranty ..................................................................... 6

1.4 Exclusion of liability..................................................................................... 6

1.5 Copyright..................................................................................................... 6

1.6 Product names and trademarks.................................................................. 6

1.7 Applicable documentation........................................................................... 6

2 Safety Notes ........................................................................................................ 7

2.1 Preliminary information ............................................................................... 7

2.2 General information .................................................................................... 7

2.3 Target group ............................................................................................... 8

2.4 Designated use ........................................................................................... 8

2.5 Transport..................................................................................................... 8

2.6 Installation/assembly................................................................................... 8

2.7 Startup/operation ........................................................................................ 9

2.8 Inspection/maintenance .............................................................................. 9

2.9 Disposal ...................................................................................................... 9

3 Integrated Safety Technology.......................................................................... 10

3.1 Safe condition ........................................................................................... 10

3.2 Safety concept .......................................................................................... 10

3.2.1 Block diagram BST .................................................................... 11

3.3 Safety function .......................................................................................... 11

3.4 Restrictions ............................................................................................... 12

4 Safety-Relevant Conditions ............................................................................. 13

4.1 Permitted unit combinations...................................................................... 13

4.2 Requirements on the installation............................................................... 14

4.3 Requirements on external safety controller .............................................. 16

4.3.1 Sample circuit for a "safety switching device"............................ 17

4.4 Requirements on startup........................................................................... 17

4.5 Requirements on the operation................................................................. 18

5 Unit Design ........................................................................................................ 19

5.1 Nameplate, type designation .................................................................... 19

5.1.1 Example: Type designation ....................................................... 19

5.1.2 Example: Nameplate ................................................................. 19

5.2 Scope of delivery of BST .......................................................................... 20

5.3 Safety-related BST brake module............................................................. 20

5.4 Terminal assignment................................................................................. 20

Operating Instructions – Safety-Related BST Brake Module

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Contents

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6 Installation ......................................................................................................... 21

6.1 Mechanical Installation.............................................................................. 21

6.1.1 Support rail mounting................................................................. 21

6.2 Electrical Installation ................................................................................. 23

6.2.1 Information on electrical installation........................................... 23

6.2.2 Double-pole safe disconnection................................................. 24

6.2.3 Single-pole safe disconnection.................................................. 25

7 Startup................................................................................................................ 26

7.1 Operating states........................................................................................ 26

7.1.1 Brake module control under normal operating conditions, e.g.

automatic operation of the plant ................................................ 26

7.1.2 Brake module control under special operating conditions, e.g.

teach or jog mode...................................................................... 27

7.1.3 Operating state display .............................................................. 27

8 Inspection/Maintenance ................................................................................... 28

8.1 Inspection and maintenance intervals....................................................... 28

8.2 Checking the brake function ..................................................................... 28

8.3 Service ...................................................................................................... 29

8.4 Unit replacement....................................................................................... 29

9 Applications....................................................................................................... 30

9.1 Disconnection of single drives via inverter (example MOVIDRIVE

9.2 Disconnection of single drives via inverter and DFS11B/21B fieldbus

interface .................................................................................................... 32

9.3 Disconnection of group drives................................................................... 33

10 Technical Data................................................................................................... 34

10.1 General technical data .............................................................................. 34

10.2 Safety-related control voltage ................................................................... 35

10.3 Safety characteristics of BST brake modules ........................................... 35

10.4 Dimension drawing of BST in control cabinet design................................ 36

11 Address List ...................................................................................................... 37

®

B) .... 31

Index................................................................................................................... 48

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Operating Instructions – Safety-Related BST Brake Module

General Information

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How to use this documentation

1

1 General Information

Safety-Rated BST Brake Module

1.1 How to use this documentation

The documentation is part of the product and contains important information. The
documentation is for everyone who works with this product.

The documentation must be accessible and legible. Make sure that persons responsible
for the system and its operation, as well as persons who work independently with the
software and the connected units from SEW-EURODRIVE, have read through the doc­umentation carefully and understood it. If you are unclear about any of the information
in this documentation, or if you require further information, contact SEW-EURODRIVE.

1.2 Structure of the safety notes

1.2.1 Meaning of the signal words

The following table shows the grading and meaning of the signal words for safety notes,
notes on potential risks of damage to property, and other notes.

Signal word Meaning Consequences if disregarded

DANGER Imminent danger Severe or fatal injuries
WARNING Possible dangerous situation Severe or fatal injuries
CAUTION Possible dangerous situation Minor injuries

NOTICE Possible damage to property Damage to the drive system or its

INFORMATION Useful information or tip: Simpli-

fies the handling of the drive
system.

environment

1.2.2 Structure of the section-related safety notes

Section safety notes do not apply to a specific action, but to several actions pertaining
to one subject. The used symbols indicate either a general or a specific hazard.

This is the formal structure of a section safety note:

SIGNAL WORD

Type and source of danger.
Possible consequence(s) if disregarded.

• Measure(s) to prevent the danger.

1.2.3 Structure of the embedded safety notes

Embedded safety notes are directly integrated in the instructions just before the descrip­tion of the dangerous action.

This is the formal structure of an embedded safety note:

• SIGNAL WORD Nature and source of hazard.

Possible consequence(s) if disregarded.
– Measure(s) to prevent the danger.

Operating Instructions – Safety-Related BST Brake Module

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General Information

Right to claim under warranty

1.3 Right to claim under warranty

A requirement of fault-free operation and fulfillment of any rights to claim under limited
warranty is that you adhere to the information in the documentation at hand. Therefore,
read the documentation before you start working with the software and the connected
units from SEW-EURODRIVE.

Make sure that the documentation is available to persons responsible for the machinery
and its operation as well as to persons who work independently on the devices. Also
ensure that the documentation is legible.

1.4 Exclusion of liability

You must adhere to this documentation and the documentation of the connected
devices from SEW-EURODRIVE to ensure safe operation and to achieve the specified
product characteristics and performance features.

SEW-EURODRIVE assumes no liability for injury to persons or damage to equipment or
property resulting from non-observance of the documentation. In such cases, any liabil­ity for defects is excluded.

1.5 Copyright

© 2011 – SEW-EURODRIVE. All rights reserved.
Unauthorized duplication, modification, distribution or any other use of the whole or any

part of this documentation is strictly prohibited.

1.6 Product names and trademarks

All brands and product names in this documentation are trademarks or registered trade­marks of their respective titleholders.

1.7 Applicable documentation

Observe the following applicable documents:

• Certificates and characteristic safety values
Make sure you always use the latest documentation and software version.
Our documentation is available in various languages for download from the SEW

homepage. If you are unclear ab
if you require further information, please contact SEW-EURODRIVE.

If required, you can order printed copies of the documentation from SEW-EURODRIVE.

out any of the information in this documentation, or

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Operating Instructions – Safety-Related BST Brake Module

2 Safety Notes

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The following basic safety notes must be read carefully to prevent injury to persons and
damage to property. The operator must ensure that the basic safety notes are read and
adhered to. Make sure that persons responsible for the plant and its operation, as well
as persons who work independently on the unit, have read through the operating instruc­tions carefully and understood them. If you are unclear about any of the information in
this documentation, or if you require further information, please contact SEW­EURODRIVE.

2.1 Preliminary information

This document contains safety-related conditions for the operation of the safety-relevant
BST brake module with safe disconnection of the brake.

The classification to category 3 according to EN 954-1, or performance level d according
to EN ISO 13849-1 applies to the control and not to the brake.

Safety Notes

Preliminary information

2

2.2 General information

Never install or start up damaged products. Submit a complaint to the shipping company
immediately in the event of damage.

All work related to transportation, storage, setup/mounting, connection, startup, mainte­nance and repair may only be carried out by qualified personnel, in strict observance of:

• The relevant detailed operating instructions

• The warning and safety signs

• All other project planning documents, operating instructions and wiring diagrams
related to the drive

• The specific regulations and requirements for the system

• The national/regional regulations governing safety and the prevention of accidents

The requirements for the safety switching device and the permitted circuit variants are
specified in detail in section "Requirements for external safety switching devices"
(page 16) and must be strictly observed.

The system/machine manufacturer must perform a system/machine-specific risk
assessment. This is to take into account the safety-relevant BST brake module as well
as the mechanical brake design.

Removing covers without authorization, improper use as well as incorrect installation or
operation may result in severe injuries to persons or damage to property.

Refer to the documentation for additional information.

Operating Instructions – Safety-Related BST Brake Module

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2.3 Target group

2.4 Designated use

Safety Notes

Target group

Only qualified personnel is allowed to perform installation, startup, fault repair and
servicing (observe IEC 60364 or CENELEC HD 384 or DIN VDE 0100 and IEC 60664
or DIN VDE 0110 as well as national accident prevention guidelines).

Qualified electricians in the context of these basic safety notes are persons familiar with
installation, assembly, startup and operation of the product who possess the required
qualifications.

Any activities regarding transportation, storage, operation, and disposal must be carried
out by persons who have been instructed appropriately.

The safety-relevant BST brake module is responsible for the power supply and control
of disk brakes from SEW-EURODRIVE. For the permitted combination of safety-related
BST brake module and SEW disk brake, refer to the section "Permitted unit combina­tions" in the "Safety-Relevant Conditions" chapter. The safety-relevant BST brake
module is intended for industrial systems and may only be used in accordance with the
information provided in SEW-EURODRIVE's technical documentation and the informa­tion given on the nameplate.

2.5 Transport

Inspect the shipment for any damage that may have occurred in transit as soon as you
receive the delivery. Inform the shipping company immediately. It may be necessary to
preclude startup.

2.6 Installation/assembly

Observe the notes in chapter "Mechanical Installation" (page 21).

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Operating Instructions – Safety-Related BST Brake Module

2.7 Startup/operation

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Safety Notes

Startup/operation

2

• When the safety-related control voltage V
is disconnected, the DC link voltage V

• The safety concept is only suitable for performing mechanical work on the system/
machine components.

• All poles must be disconnected from the supply system when work is carried out on
the electrical section of the system. Dangerous voltages may still be present for up
to 10 minutes after disconnection from the power supply system.

• You have to take into account that, in case of a fault, the application time of the
connected brake is longer, which means the drive might coast.

– For maximum brake application times, refer to chapter "Technical Data" of the

operating instructions for the BST and SEW disk brakes.

– Note: If coasting to a halt results in application-dependent hazards, take addi-

tional protective measures (e.g. movable covers with closure), which cover the
hazardeous area until persons are no longer in danger.

– The additional protective covers must be designed and integrated to meet the

requirements stipulated in EN ISO 12100:2010 and the requirements determined
for the machine based on the risk assessment.

– After activating the stop command, access to the machine must remain blocked

until the drive has reached standstill, or the access time has to be determined to
ensure that an adequate safety distance is maintained.

• The states of LED V1 and LED V2 must not be regarded as safety-relevant. The fact
that the LED V1 and LED V2 are no longer illuminated does not indicate that the
safety-relevant BST brake module is de-energized and the brake is applied. Even if
LED V1 and LED V2 are not illuminated, DC link voltage V
the BST brake module.

• The safety-related BST brake module does not detect a mechanical fault (such as
brake lining wear) of the disk brakes of SEW-EURODRIVE.

24 V safe

DC link

/ functional control voltage V

is still present at the brake module.

might be present at

DC link

24 V in

2.8 Inspection/maintenance

Observe the notes in chapter "Inspection/Maintenance" (page 28).

2.9 Disposal

Dispose the BST in accordance with the material structure and the regulations in force
for instance as:

•Iron

• Copper

•Aluminum

• Plastic

Operating Instructions – Safety-Related BST Brake Module

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Integrated Safety Technology

Safe condition

3 Integrated Safety Technology

The safety technology of the safety-related BST brake module described in this docu­ment has been developed and tested in accordance with the following safety require­ments:

• Category 3 according to EN 954-1

• Performance level d according to EN ISO 13849-1

This was certified by TÜV Nord. A copy of the TÜV certificate can be obtained from
SEW-EURODRIVE.

3.1 Safe condition

Safety-relevant use of the BST brake module means the de-energized condition of
the connected brake is defined as safe condition. This is the basis of the safety

concept.

3.2 Safety concept

• The safety-related BST brake module enables the connection of an external fail-safe

• Disconnecting the safe control voltage V

• Instead of separating the brake control galvanically from the power supply using

safety switching device/safety controller. The safety switching device disconnects
the safe control voltage V
stop device) is activated.

disconnected from the power supply. The power supply required for releasing the
connected brake is interrupted safely.

contactors or switches, the disconnection procedure described here prevents the
power semiconductors in the safety-related BST brake module from being activated,
in this way ensuring safe disconnection. This means that all connected brakes are
de-energized although the supply voltage is still present at the safety-related BST
brake module.

24 V safe

when a connected control device (e.g. emergency

24 V safe

means the connected brake is

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Operating Instructions – Safety-Related BST Brake Module

3.2.1 Block diagram BST

34

56

13 14 15

12

[1]

[4]

[3]

[2]

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[1] DC link voltage input V
[2] Brake output (terminals 13/14/15)
[3] Functional control voltage input V
[4] Safety-related control voltage input V

Integrated Safety Technology

Safety function

(terminal 1/2)

DC link

(terminal 3/4)

24 V in

24 V safe

(terminal 5/6)

3

9007201124185483

3.3 Safety function

The following drive-related safety function can be used:

• SBC (Safe Brake Control according to IEC 61800-5-2)
The SBC function safely de-energizes the connected brake by disconnecting the

safety-related control voltage V
disconnected using a suitable external safety switching device/safety controller.

INFORMATION

Safety-related brake control must be carried out using the safety-related control
voltage V

24 V safe

(terminal 5/6) only.

24 V safe

. The safety-related control voltage must be

Operating Instructions – Safety-Related BST Brake Module

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3.4 Restrictions

Integrated Safety Technology

Restrictions

WARNING

Voltage is still present at the DC link connection of the frequency inverter even when
disconnecting the safety-related control voltage V
V

Severe or fatal injuries from electric shock.

• If work is carried out on the electrical section of the brake system, the supply

.

24 V in

voltage must be disconnected using an external maintenance switch.

24 V safe

/ functional control voltage

INFORMATION

• The safety concept is only suitable for performing mechanical work on the system/
machine components.

• A system/machine-specific risk assessment must be carried out by the system/
machine manufacturer and be observed when using the drive system with BST.

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Operating Instructions – Safety-Related BST Brake Module